Brochure surface metrology for manufacturing

In the automotive industry, technical surfaces tip the scales when it comes to high-precision mechanics and their performance. The dimensional tolerance has a decisive influence on a product’s fuel and energy efficiency, eco-friendliness and durability.

From sealing surfaces, to the drivetrain and shock absorbers and to injection systems, there are a multitude of applications “being put to the test”. Absolute precision when contactlessly determining flatness, parallelism, form parameters, surface parameters, heights and steps is vitally important. And what should you use to ensure this? The surface measurement systems from Polytec, of course!

Measuring Drive Technology with Nanometer Precision

Technical surfaces with purposefully created microstructures and nanostructures are key to reducing wear and energy consumption. Manufacturers only stand a chance of improving their products if they use faster, more reliable measuring technology that is repeatable at any time.

Polytec's surface measurement systems allow you to record 3D structures quickly and extensively. You can use special Polytec products within the production line too. Polytec will see you right – even if you need to perform measurements in holes up to 70 mm deep.

Related products

The TopMap In.Line’s compact design means it can be easily integrated into the production line and quickly carries out checks on differently reflective surfaces. Steps, larger ripples or other surface structures do not pose any problems here.

The all-in-one 3D optical surface profiler from Polytec. The precision of a white-light interferometer, complemented by chromatic confocal sensors to overcome form deviations and any roughness determined with one device. Pro.Surf+ measures topography over a...

Checking Tightness without Contact

The quality of sealing surfaces has a decisive influence on connections not being ‘leaky’ in the long run. If this is to be achieved, the surface’s geometric properties must be defined as precisely as possible so that the intended function – in other words, “leak-tightness” – is fulfilled. Leaks can occur particularly if the contact surfaces’ form deviation is outside defined tolerances.

This risk can be prevented by using Polytec’s surface measurement systems. Using these products allows you to characterize tightness not only in the lab, but also during production. Thanks to the contactless measuring method, both the form and consistency of the sealing surfaces to be inspected are maintained and the measurement results can be repeated at any time. The Polytec systems are easy to use and make for a fast analysis process.

Documents

A Practical Example:

Polytec surface measurement systems are “in their element” in all production operations where tight cycle times have to be complied with. This situation is a particularly frequent one in the automotive industry – for example where injection systems, Piezo common rail systems and compressors are used, and for motor development in general.

Related products

The TopMap In.Line’s compact design means it can be easily integrated into the production line and quickly carries out checks on differently reflective surfaces. Steps, larger ripples or other surface structures do not pose any problems here.

The all-in-one 3D optical surface profiler from Polytec. The precision of a white-light interferometer, complemented by chromatic confocal sensors to overcome form deviations and any roughness determined with one device. Pro.Surf+ measures topography over a...

Keeping Tolerances Tight in Injection Systems

Maximum precision and compliance with the tightest tolerances are essential for ensuring the energy efficiency of subcomponents and the injection system as a whole. To achieve this, it is necessary to determine not only surfaces' roughness, but also form deviation t, using high-precision instruments with a view to controlling a reliable and high-quality manufacturing process.

And what should you use to complete these measuring tasks? The surface measurement systems from Polytec, of course! They are based on the principle of white-light interferometry and achieve extremely high nanometer resolution. They make “in-line” surface characterization - in other words, performing measurements during production - quick and easy for you. The results you achieve in doing so are traceable and comply with both national and international standards.

A Practical Example:

The demands placed on modern fuel injection systems in the automotive industry are very high to ensure that fuel can combust in an ever cleaner and more efficient way. To meet these increased expectations made of the injection process, the individual components’ surfaces must be manufactured with very tight tolerances. This is a task where Polytec surface measurement systems really do play to their strengths.

Related products

The TopMap In.Line’s compact design means it can be easily integrated into the production line and quickly carries out checks on differently reflective surfaces. Steps, larger ripples or other surface structures do not pose any problems here.

The all-in-one 3D optical surface profiler from Polytec. The precision of a white-light interferometer, complemented by chromatic confocal sensors to overcome form deviations and any roughness determined with one device. Pro.Surf+ measures topography over a...

Example: Shock Absorbers

Both the surface quality of compensating discs and the pistons are crucial in shock absorber development if a quality product is to be created. That’s because pistons and compensating discs are key components for correct shock absorber function. They control how a shock is absorbed, since they act like a valve for the liquid or gas inside.

Form deviations outside of defined tolerances at moving parts’ contact points may lead to leakage. Precise control and monitoring in the manufacturing process is essential if the targeted absorption effect is to be guaranteed. Both of these tasks are simply inconceivable without production measuring technology. Tactile surface metrology methods used to detect these shortcomings are very time-consuming and only provide an illustration for part of the surface.

With Polytec’s TMS instruments, you not only save some time, but you’re also given a detailed measurement of the entire surface, and particularly of such high-performance components’ critical parameters – such as flatness, parallelism and step height.

Documents

Related products

Being a complete measuring station, the TopMap Metro.Lab is ideally suited to large-area topographies on almost all surfaces. Since it offers great value for money, it is also attractive for smaller companies with fewer tasks.

The TopMap In.Line’s compact design means it can be easily integrated into the production line and quickly carries out checks on differently reflective surfaces. Steps, larger ripples or other surface structures do not pose any problems here.

With the TMS-1200 TopMap µ.Lab, you can characterize microstructures’ surfaces with a very high lateral resolution. The optical profilometer contactlessly determines parameters such as texture, flatness, ripple and roughness on both fine and sensitive...

Reliable Pass-Fail Analysis in-line or at-line

In industrial processes, everything depends on high precision during the manufacturing process, and accordingly tight tolerances must be complied with if this is to be achieved. Modern production measuring technology ensures that these limits are complied with at all times. After all, you will only continuously achieve high product quality if you use precise instruments.

Optical surface measurement systems that can be integrated in the production line as in-line applications detect defective parts within the process. These results enable you to take precautions that adjust production operations in good time. Reliable pass/ fail decisions in production lines increase efficiency and keep your reputation high.

Polytec's white-light interferometers allow you to contactlessly examine both structures and surfaces in the blink of an eye. In many cases, an object’s entire topography needs to be checked prior to certification. Polytec TopMap surface measuring systems increase testing efficiency due to its large areal measurements.

Multi-sample measurements for efficient production testing

Related products

The TopMap In.Line’s compact design means it can be easily integrated into the production line and quickly carries out checks on differently reflective surfaces. Steps, larger ripples or other surface structures do not pose any problems here.

The all-in-one 3D optical surface profiler from Polytec. The precision of a white-light interferometer, complemented by chromatic confocal sensors to overcome form deviations and any roughness determined with one device. Pro.Surf+ measures topography over a...

Check and optimize friction

When it comes to tribology – that is, the science of friction, lubrication and wear – surface properties play a very important role. These parameters can be controlled as desired by simply changing the surface. However corresponding measuring instruments are needed for this, since only powerful surface measurement methods enable development of suitable components. The perfect conditions for checking wear and optimizing lubrication are only created by refining surfaces.

The surface measurement systems from Polytec allow you to measure a variety of surfaces, whether they’re polished, rough or textured. Both the form and the function of the test object are maintained thanks to the contactless measuring method. Polytec products provide you with excellent resolution, right down to the nanometer range. You can choose to use integrated filters for different reflections. The special software is easy to use and can be adapted to your working conditions without a single problem.

A Practical Example:

Continuous lubrication and even lubrication distribution can be both determined and optimized in air bearings using the TopMap instruments.

Related products

Being a complete measuring station, the TopMap Metro.Lab is ideally suited to large-area topographies on almost all surfaces. Since it offers great value for money, it is also attractive for smaller companies with fewer tasks.

The TopMap In.Line’s compact design means it can be easily integrated into the production line and quickly carries out checks on differently reflective surfaces. Steps, larger ripples or other surface structures do not pose any problems here.

The all-in-one 3D optical surface profiler from Polytec. The precision of a white-light interferometer, complemented by chromatic confocal sensors to overcome form deviations and any roughness determined with one device. Pro.Surf+ measures topography over a...

With the TMS-1200 TopMap µ.Lab, you can characterize microstructures’ surfaces with a very high lateral resolution. The optical profilometer contactlessly determines parameters such as texture, flatness, ripple and roughness on both fine and sensitive...